I had the idea for this one for some time, but just never got around to putting it into action. I saw MustangDave found a 3D Head scan on the net by Lee Perry-Smith, and I thought hmm... that looks a little like Doug Bradley... So I set about giving it some eyes (as the scan had none) and creating a back piece for the head, a neck base and of course sculpting out the lines in the face, which I have to admit was pretty fun. This was not a long job. If I wanted to to a good 2-3 hour job on it I would have made the lines alot thinner and more defined, but I wanted to make sure they came out well on ANY printer.. so the whole painting and pin process was easier. I would have also put divets in where the pins are supposed to go to make it easier, but literally 100 of those would have taken me a while, and I just wanted to print it!!!

Pins
There are about 100 pins in his head. I used 1 Inch lengths. Yes, they are a little long but I wanted a bit more of a punch when you see it, and because they are too long, they can be shortened if I wish, if you do them too short, you are well and truly in a mess, and you will need to start over. Cut yours to whatever length you like.
If we want to get technical, the length of the pins are actually the same as the width of his eye sockets in the movie. To achieve this with this model, I would need to print it much bigger to have 1.75mm filament work effectively with this print. Look at my raw print.. see the banding line round the back of the ear? my flashforge for some reason right now cannot do more than about 14cm high without going crapola... so this was about as big as I could print the head in one piece. Also, when my kids saw this on the shelf with the gigantic pins sticking out of it's head, it achieved it's desired result "OMG!!!!"

how to make the pins
I used scraps of filament, cut them all to 1 inch, threw them on the heatbed until they got soft and straightened them out with my fingers. I then pushed the ends against the hot end when it was semi-hot and flattened them out like nails. I glued them in one by one and them painted them at the very end, but there is 10 ways to do it, it's up to you. I just used quick drying super glue and some silver paint.